Joint optimisation of production rate and preventive maintenance in machining systems

Abstract

This paper studies an integrated control strategy of production and maintenance for a machining system which produces a single type of product to meet the constant demand. Different from previous research, we assume in this study that during the production, the production rate not only influences the life of cutting tool, but also the reliability of the machine. Both the replacement of cutting tool and the preventive maintenance (PM) of machine are considered in this paper. The machine is preventively maintained at the Nth tool replacement or correctively repaired at the machine failure, whichever occurs first. PM and corrective repair may cause shortage which can be reduced by controlling inventory. There are two decision variables p and N, where p denotes the production rate and N denotes the number of cutting tool replacement before the PM is performed. An integrated model is developed to simultaneously determine the optimal production rate and PM policy that minimise the total expected cost per unit item produced. Finally, an illustrative example and sensitivity analysis are given to demonstrate the proposed model.

Keywords:

• machining system
• production
• inventory
• tool replacement
• load-dependent machine reliability
• preventive maintenance